Carbonylation process using bound silver and/or copper mordenite catalysts

Abstract

Process for the carbonylation of a carbonylatable reactant selected from at least one of dimethyl ether and methanol, by carbonylating the carbonylatable reactant with carbon monoxide in the presence of a catalyst to produce a carbonylation product selected from at least one of methyl acetate and acetic acid. The catalyst is formed by compositing a mordenite loaded with at least one of silver and copper, with an inorganic oxide binder.

The invention claimed is: 
     
       1. A process for the carbonylation of a carbonylatable reactant selected from at least one of dimethyl ether and methanol, said process comprising carbonylating said carbonylatable reactant with carbon monoxide in the presence of a catalyst to produce a carbonylation product selected from at least one of methyl acetate and acetic acid, which catalyst is formed by compositing a mordenite loaded with at least one of silver and copper, with an inorganic oxide binder. 
     
     
       2. A process according to  claim 1  wherein the compositing of the metal loaded mordenite with the binder is carried out by slurry mixing or by dry mixing. 
     
     
       3. A process according to  claim 1  wherein the mordenite loaded with at least one of silver and copper is calcined prior to being composited with the binder. 
     
     
       4. A process according to  claim 1  wherein the catalyst is calcined. 
     
     
       5. A process according to  claim 1  wherein the binder is selected from the group consisting of silicas, aluminas, silica-aluminas, magnesium silicates, magnesium aluminium silicates, titanias, zirconias and clays. 
     
     
       6. A process according to  claim 5  wherein the binder is selected from an alumina and a silica-alumina. 
     
     
       7. A process according to  claim 1  wherein the binder has a mesoporosity in the range 1 to 500 m2/g as measured by nitrogen BET. 
     
     
       8. A process according to  claim 1  wherein the binder has a microporosity in the range 1 to 100 m2/g as measured by nitrogen BET. 
     
     
       9. A process according to  claim 1  wherein the binder contains the metals of Group 1 and Group 2 of the Periodic Table of Elements and iron in a total amount in the range greater than 0 to 10 wt %. 
     
     
       10. A process according to  claim 1  wherein the binder is present in the catalyst in an amount in the range 10 to 80% by weight of the catalyst. 
     
     
       11. A process according to  claim 1  wherein the at least one of copper and silver is loaded onto the mordenite by ion-exchange. 
     
     
       12. A process according to  claim 1  in which process there is also present hydrogen. 
     
     
       13. A process according to  claim 1  wherein the carbonylatable reactant is dimethyl ether and the process is conducted as an anhydrous process. 
     
     
       14. A process according to  claim 1  wherein the carbonylation product comprises methyl acetate and at least some of the methyl acetate is hydrolysed to acetic acid.